Fiber-wrapped smokeless tobacco product

ABSTRACT

A fiber-wrapped smokeless tobacco product includes smokeless tobacco and a plurality of polymeric fibers surrounding the smokeless tobacco. The polymeric fibers can have a basis weight of 5 gsm or less and a diameter of less than 100 microns. In some cases, the polymeric fibers are melt-blown polymeric fibers. In some cases, the polymeric fibers are centrifugal force spun polymeric fibers. A method of preparing a fiber-wrapped smokeless tobacco product includes melt-blowing or centrifugal force spinning a plurality of polymeric fibers to create an polymer deposition zone and passing a body comprising smokeless tobacco through the polymer deposition zone. In some cases, an electrostatic charge can be applied to the plurality of polymeric fibers, the body, or a combination thereof. In some cases, a spin is applied to the body when passing through the polymer deposition zone.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional application of, and claims the benefitof priority under 35 U.S.C. §121 to, U.S. application Ser. No.14/212,537 filed Mar. 14, 2014, which claims the benefit of priorityunder 35 U.S.C. §119(e) to U.S. Application No. 61/786,295 filed Mar.14, 2013. The contents of all applications are incorporated herein byreference for all purposes in their entirety.

WORKING ENVIRONMENT

This disclosure generally relates to a smokeless tobacco productincluding wrapping of polymeric fibers and methods of making suchproducts.

Smokeless tobacco is tobacco that is placed in the mouth and notcombusted. There are various types of smokeless tobacco including:chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewingtobacco is coarsely divided tobacco leaf that is typically packaged in alarge pouch-like package and used in a plug or twist. Moist smokelesstobacco is a moist, more finely divided tobacco that is provided inloose form or in pouch form and is typically packaged in round cans andused as a pinch or in a pouch placed between a cheek and gum of an adulttobacco consumer. Snus is a heat treated smokeless tobacco. Dry snuff isfinely ground tobacco that is placed in the mouth or used nasally.Smokeless Tobacco can be pouched in a fabric using a pouching machinewhere a supply of pouching material sealed around a deposit of smokelesstobacco material.

SUMMARY

A fiber-wrapped smokeless tobacco product includes smokeless tobacco anda plurality of polymeric fibers surrounding the smokeless tobacco. Thepolymeric fibers can have a basis weight of 30 grams per square meter(gsm) or less, 20 gsm or less, 10 gsm or less, or 5 gsm or less. Thepolymeric fibers can have diameters of less than 100 microns. In somecases, the polymeric fibers are melt-blown polymeric fibers. In somecases, the polymeric fibers are force-spun polymeric fibers. A method ofpreparing a fiber-wrapped smokeless tobacco product includesmelt-blowing or centrifugal force spinning a plurality of polymericfibers to create an polymer deposition zone and passing a bodycomprising smokeless tobacco through the polymer deposition zone. Insome cases, an electrostatic charge can be applied to the plurality ofpolymeric fibers, the body, or a combination thereof. In some cases, aspin is applied to the body when passing through the polymer depositionzone. In some cases, the polymer fibers wrap and seal the bodysimultaneously.

The fiber-wrapped smokeless tobacco products provided herein provide aunique tactile and flavor experience to an adult tobacco consumer. Inparticular, the polymeric fibers can provide a smoother mouth textureand improved access to the smokeless tobacco, improved porosity, andimproved fluid delivery as compared to a traditional pouching material,but still retain the smokeless tobacco. Moreover, the methods providedherein can result in a seamless wrapping of polymeric fibers, which canreduce mouth irritation. Furthermore, the polymeric fibers providedherein can be more elastic and can permit an adult tobacco consumer tochew/squeeze the fiber-wrapped smokeless tobacco product and mold theproduct into a desired shape (e.g., to comfortably conform the productbetween the cheek and gum). As compared to a typical pouch paper, thefiber wrappings provided herein can be softer, have a lower basisweight, and act as less of a selective membrane. The methods of formingpouched smokeless tobacco products and the fabrics provided herein arealso described. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined to form afiber-wrapped smokeless tobacco product that becomes looser when placedin a mouth of an adult tobacco consumer, yet remains generally cohesive.The polymeric fibers can also be a composite of multiple materials,which may include both mouth-stable and mouth-dissolvable materials.

The products and methods described herein can also be applied to otherorally consumable plant materials in addition to smokeless tobacco. Forexample, some non-tobacco or “herbal” compositions have also beendeveloped as an alternative to smokeless tobacco compositions.Non-tobacco products may include a number of different primaryingredients, including but not limited to, tea leaves, red clover,coconut flakes, mint leaves, citrus fiber, bamboo fiber, ginseng, apple,corn silk, grape leaf, and basil leaf. In some cases, such a non-tobaccosmokeless product can further include tobacco extracts, which can resultin a non-tobacco smokeless product providing a desirable mouth feel andflavor profile. In some cases, the tobacco extracts can be extractedfrom a cured and/or fermented tobacco by mixing the cured and/orfermented tobacco with water and/or other solvents and removing thenon-soluble tobacco material. In some cases, the tobacco extracts caninclude nicotine. In some cases, a pouched non-tobacco product has anoverall oven volatiles content of between 10 and 61 weight percent.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the methods and compositions of matter belong. Althoughmethods and materials similar or equivalent to those described hereincan be used in the practice or testing of the methods and compositionsof matter, suitable methods and materials are described below. Inaddition, the materials, methods, and examples are illustrative only andnot intended to be limiting. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety.

DESCRIPTION OF DRAWINGS

FIG. 1A is a flow chart showing an exemplary method of formingfiber-wrapped smokeless tobacco products.

FIG. 1B depicts a perspective view of an embodiment of a fiber-wrappedsmokeless tobacco product with a predetermined shape.

FIG. 1C depicts a substantially cylindrical container retaining aplurality of fiber-wrapped smokeless tobacco products.

FIGS. 2A and 2B are schematic drawings of an exemplary method of formingfiber-wrapped smokeless tobacco products.

FIG. 2C depicts an exemplary arrangement of polymer orifices and airorifices for a melt-blowing apparatus.

FIGS. 3A-3E illustrate a force-spinning apparatus.

FIGS. 4A-4N depict alternative shapes for the fiber-wrapped smokelesstobacco product.

FIG. 5 is a chart showing the release pattern of methyl salicylate(i.e., wintergreen) from fiber-wrapped smokeless tobacco products andfor a Skoal XTRA WG Pouch in a simulated masticator test.

FIGS. 6A-6C depict the debris remaining in simulated masticator cell forthe simulated masticator test of Figure for each tested fiber-wrappedsmokeless tobacco product.

FIGS. 7A-7C depict fiber-wrapped smokeless tobacco products after thesimulated masticator test of FIG. 5.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This disclosure provides fiber-wrapped smokeless tobacco products andmethods and materials for producing fiber-wrapped smokeless tobaccoproducts. In some cases, polymeric fibers have a diameter of less than100 microns and are deposited onto a body including smokeless tobacco.The polymeric fibers can wrap around the body and form amoisture-permeable porous surface. This disclosure is based, in part, onthe discovery that the resulting fiber-wrapped smokeless tobaccoproducts provide a unique tactile and flavor experience to an adulttobacco consumer. In particular, the polymeric fibers can provide asmooth mouth texture, bind/encase/encapsulate the smokeless tobaccoduring use, but give the adult tobacco consumer good access to thesmokeless tobacco and any flavor contained therein. As compared to atypical pouch paper, the polymeric fibers can be softer, be free ofseams, have a lower basis weight, act as less of a selective membrane,and greater moldability/manageability.

The methods of forming the fiber-wrapped smokeless tobacco products arealso provided herein. In some cases, a body including smokeless tobaccomaterial is passed through a stream of melt-blown polymeric fibers toform an outer layer of melt-blown polymeric fibers around the body. Insome cases, a body including smokeless tobacco material is passedthrough a stream of force-spun polymeric fibers to form an outer layerof force-spun polymeric fibers around the body. The methods describedherein result in products that remain cohesive and are less likely tobreak apart during packaging, handling, shipping, and during use byadult tobacco consumers. In some cases, the polymeric fibers provide asoft and highly porous coating around the smokeless tobacco. The methodsdescribed herein can enrobe and/or wrap smokeless tobaccos that are notsuitable for being pouched using a typical pouching operation, forexample smokeless tobaccos having an average partial aspect ratio ofgreater than 3 (e.g., long-cut smokeless tobacco) and/or high moisturetobacco (e.g., a tobacco having an OV content of greater than 47 weightpercent).

The described combinations of the polymeric material and smokelesstobacco can provide a softer mouth feel. Moreover, in some cases, thepolymeric material can be elastic or pliable (e.g., a polymericpolyurethane such as DESMOPAN DP 9370A available from Bayer) thusforming a smokeless tobacco product that can tolerate being “worked”(e.g., chewed or squeezed) in the mouth without the tobacco dispersingwithin the mouth. For example, the smokeless tobacco product can beworked to provide flavor and/or to comfortably conform between the cheekand gum. In some cases, combinations of mouth-stable andmouth-dissolvable polymeric materials are combined with a body includingsmokeless tobacco material to provide a product that becomes looserafter being placed in a mouth of an adult tobacco consumer, yet remainsgenerally cohesive. Polymeric structural fibers can also be a compositeof multiple materials, which may include both mouth-stable andmouth-dissolvable materials.

The fiber-wrapped smokeless tobacco products include polymericstructural fibers that form a nonwoven network against and around a bodyof smokeless tobacco material. As used herein, the term “nonwoven” meansa material made from fibers that are connected by entanglement and/orbonded together by a chemical, heat or solvent treatment where thematerial does not exhibit the regular patterns of a woven or knittedfabric. Smokeless tobacco, for example, can be introduced into a streamof melt-blown and/or force spun polymeric material as a preformed body.In some cases, the stream of melt-blown and/or force spun polymericmaterial will coat the smokeless tobacco to form a soft and porouscoating around the smokeless tobacco. In some cases, polymericstructural fibers can be produced and contacted with smokeless tobaccowhile the polymeric fibers are still above their melt temperature. Insome cases, polymeric structural fibers can be cooled (e.g., quenched)prior to contacting or when fibers contact a body including smokelesstobacco material. In some cases, the polymeric structural fibers aretreated with a surfactant and/or other additives to increasepermittivity of the fiber wrapping.

The fiber-wrapped smokeless tobacco product can also be dimensionallystable. As used herein, “dimensionally stable” means that thefiber-wrapped smokeless tobacco product retains its shape under its ownweight. In some cases, a fiber-wrapped smokeless tobacco product isflexible, yet can be picked up at one end without the force of gravitycausing the fiber-wrapped smokeless tobacco product to bend or sag. Insome cases, the fiber-wrapped smokeless tobacco product can be easilydeformable.

Although other methods of producing the fiber-wrapped smokeless tobaccoproduct are also contemplated, various methods of producing variousfiber-wrapped smokeless tobacco products are discussed in more detailbelow.

Methods of Manufacture

One method of preparing the smokeless tobacco product includes directingpolymeric fibers having a diameter of less than 100 microns (or lessthan 50 microns, or less than 30 microns, or less that 10 microns, orless than 5 microns, or less than 1 microns, or less that 0.5 microns,or less than 0.1 microns, or less than 0.05 microns) towards thesmokeless tobacco such that the polymeric fibers enrobe and conform tothe surface topography of the tobacco fibrous structures. Theseprocesses can be controlled such that the resulting composite tobaccoproduct has a moisture-permeable porous surface and an overall ovenvolatiles content of between 4 and 61 weight percent. In some cases, theprocess is controlled to have an overall oven volatiles content of atleast 30 weight percent.

FIG. 1A is a flow chart 160 showing an example of how the fiber-wrappedsmokeless tobacco product can be made, collected, and packaged. In somecases, the smokeless tobacco T can be cured tobacco. Tobacco T can beadded to a mixer. An optional binder B, and optionally flavorants Fand/or other additives are mixed with the tobacco T in mixing step 162.For example, tobacco T can be long cut tobacco having an oven volatilescontent of 10-61 weight percent. Optional binder B can be TICALOID LITEPowder. Optional flavorants F and other additives can include, forexample, a mint flavoring, a sweetener, and a pH modifier. The mixingstep 162 can occur in any commercially available countertop mixer orindustrial mixer, for example a HOBART 40 lbs mixer or a FORBERG 250 lbsPaddle Mixer. Water can be added to the tobacco prior to or during themixing process to alter the total oven volatiles content of the finalfiber-wrapped smokeless tobacco product. The oven volatiles content canalso be modified by heating the mixture. In some cases, a commerciallyavailable smokeless tobacco product (e.g., SKOAL Long Cut) can be mixedwith a binder (e.g., TICALOID LITE Powder) to form the mixture, whichcan then be shaped into one or more bodies.

In some cases, the bodies provided herein can have less than 1% byweight of binder, less than 0.5% by weight of binder, less than 0.3% byweight of binder, less than 0.2% by weight of binder, less than 0.1% byweight of binder, or less than 0.05% by weight of binder. In some cases,the smokeless tobacco body includes one or more binders, such as ahydrocolloid, in an amount of between 0.05 weight percent and 0.8 weightpercent. In some cases, the smokeless tobacco products include between0.1 and 0.5 weight percent binder. For example, the preformed smokelesstobacco products can include between 0.2 and 0.4 weight percent of abinder that includes guar gum, xanthan gum, cellulose ether, or similarmaterials or a combination thereof.

The molding step 164 can include depositing the mixture into a mold. Insome cases, the mixture is deposited into an open mold plate including aplurality of identically shaped cavities. The molding step 164 caninclude applying pressure to the mixture. The pressure can be applied asinjection pressure applied to the mixture as it is forced into a closedcavity or by compressing each cavity filled with the mixture. Thepressure used during the molding process impacts that amount ofcompression experienced by the mixture and thus the material propertiesof the mixture. In some cases, 50-300 lbs. of injection pressure is usedto deliver the mixture into a plurality of mold cavities. The molds canbe filled with continuous or intermittent pressure. A screw pump can beused to apply the pressure to the mixture. For example, a Formax®machine (e.g., the FORMAX F-6 and F-19 units) can be used to inject themixture into cavities in a mold plate. For example, such a process isdescribed in U.S. Patent Application Publication No. 2012/0024301, whichis hereby incorporated by reference. In some cases, the mold cavitieshave shapes corresponding to the preformed product shapes shown in FIGS.1B, 1C, and 4A-4N. In some cases, the mold cavities can have othershapes. In some cases, the mold cavities have a volume sized to createshaped smokeless tobacco bodies having a mass of, for example, about2.35 grams. The edges and corners of the mold can be rounded to permitthe shaped smokeless tobacco bodies to be easily released from the moldand be comfortable in the mouth of an adult tobacco consumer. In somecases, the molding step 164 can include extruding smokeless tobaccomaterial (optionally with binders, flavorants, and other additives) andcutting the extruded smokeless tobacco material to form the preformedbodies.

The passing step 170 includes passing the bodies through a polymerdeposition zone where a stream of polymeric fibers contact the preformedbodies and coats surfaces of the preformed bodies with polymeric fibers.In some cases, the passing step 170 includes dropping the bodies througha polymer deposition zone. In some cases, a holding device can be usedto control the passage of the bodies through a polymer deposition zone.A variety of techniques can be used to ensure that the stream ofpolymeric fibers wrap around all sides of the bodies. These techniquescan be used in a variety of combinations. In some cases, multiplestreams of polymeric fibers can be directed towards a product path alongdifferent directions. For example, a single melt-blowing device can havea bent or curved array of spinnerets so that melt-blown polymeric fibersconverge towards a drop path. In some cases, multiple polymer fiberproducing devices are arranged so that multiple streams converge towardsa product path. In some cases, multiple polymer producing devices arearranged in series along a drop path directed in different directions(e.g., opposite directions). In some cases, a single body can be passedthrough one or more streams multiple times. In some cases, spin can beapplied to the bodies as they pass (e.g., drop) through the stream(s).For example, air jets can be used to spin bodies as they pass (e.g.,drop) through the stream(s).

In some cases, the passing step 170 can include one or more holdingdevices (e.g., needle-like devices) that are pressed into the bodies andused to move the bodies through the polymer deposition zone. Forexample, two needle-like devices can be pushed into opposite sides of abody to secure the body. The needle-like devices can be made of metaland have a sharp point. In some cases, a single dowel can be pressedthrough the entire body to hold the body. In some cases, the needle(s)or dowel(s) can have a diameter that is sufficiently small so as toprevent the passage of significant amounts of tobacco through theuncovered portion of the body created by the needle(s) and/or dowel(s).In some cases, the needle(s) and/or dowel(s) can have a diameter of lessthan 500 microns, less than 100 microns, less than 50 microns, or lessthan 10 microns. The holding devices can be used to control the speed ofmovement of the body through the polymer deposition zone. The holdingdevices can be used to rotate the bodies as they pass through thepolymer deposition zone, which can ensure that all sides of the body areexposed to the polymer stream and that fibers are wrapped around thebody. The holding devices can be heated. A heated needle and/or dowelcan minimize build-up of excess fibers on the needle or dowel while thebody is being wrapped with the polymeric fibers. For example, anelectric heater can be applied to a metal needle by heating a portion ofthe needle being held. In some cases, holding devices can be heated byinduction. In some cases, multiple holding devices can be used to rotatethe bodies through the polymer deposition zone along different axes. Forexample, two pairs of needles could be selectively engaged with a bodyto rotate a body about a first axis that is acute with the direction ofthe polymer flow followed by as second axis that is perpendicular to thefirst axis and acute with the direction of polymer flow. Other motionprofiles are also possible. After a body is wrapped (e.g., enrobed),they can be ejected from the holding device(s). For example, a pair ofneedles can be moved apart to allow a body to drop. In some cases, aplate can slide over a surface of a holding device to eject the body.

In some cases, an electrostatic charge can be applied to the bodiesand/or the polymer during step 170. When electrostatically charged, apreformed body can draw fibers directly onto the body, which canincrease the efficiency of the wrapping process and minimize polymericfibers that bypass the body. An electrostatic charge can also improvethe coverage around the back side of the preformed body. In some cases,a holding device (e.g., one or more needle-like structures pushed intothe body) can be used to apply an electrostatic charge to the body. Insome cases, the polymer is electrostatically charged (e.g., as thepolymer passes through the spinnerets).

The fibers produced in step 182 can be produced by melt-blowing and/orcentrifugal force spinning, which are each described below. The polymerP can be any suitable polymers usable in a melt-blowing and/orcentrifugal force spinning process, such as polypropylene, polyurethane,cellulose, polyethylene, PVC, viscose, polyester, and PLA. As shown inFIG. 1A, a polymer P (e.g., polypropylene) is added to a polymerproducing device as part of step 182.

The melt-blown and/or centrifugal force spun polymeric fibers can bequenched (i.e., rapidly cooled to below their melt temperature) prior toor upon contacting the smokeless tobacco in step 184. For example, wateror other liquid can be sprayed into a polymeric fiber stream prior tocontact with a body including smokeless tobacco to quench the polymericfibers. In some cases, the polymeric fibers can be quenched with asurfactant S, as shown in FIG. 1A. In some cases, the polymeric fiberscan be cooled to below the melt temperature after contact with a bodyincluding smokeless tobacco.

The polymeric fibers produced in step 182 can have a diameter of lessthan 100 microns, less than 50 microns, less than 30 microns, less that10 microns, less than 5 microns, less than 1 microns, less that 0.5microns, less than 0.1 microns, less than 0.05 microns, or less than0.01 microns. In some cases, melt-blown polymeric fibers can have adiameter of between 0.5 and 5 microns. In some case, force-spunpolymeric fibers can have a diameter of between 10 nanometers and 1micron. The flow of the polymeric fibers and the dimensions of thepolymeric fibers as they exit a melt blowing or centrifugal forcespinning apparatus result in an intimate contact between the fibers andthe smokeless tobacco such that the polymeric fibers conform to thesurface topography of the tobacco fibrous structures.

A collecting and packaging step 190 can include catching thefiber-wrapped smokeless tobacco products and packaging them in package(e.g., container). In some cases, the fiber-wrapped smokeless tobaccoproducts are collected on a conveyor belt and transported to a positiondevice that places a plurality of products in a container. For example,FIG. 1C depicts a container 300 including a plurality of fiber-wrappedsmokeless tobacco products 100. After being placed in the interior space301 of container 302, a lid 304 is mated with the connection rim 303 ofthe bottom container 302. A label can be applied to the closed containersystem 300 (e.g., applied to the outer cylindrical sidewalls of thebottom container 302 and the lid 304). Shrink wrap can also be appliedto the closed container system 300. A plurality of filled, labeled, andshrink wrapped container systems 300 can then be placed in a box andshipped to a retail location.

Each fiber-wrapped smokeless tobacco product 100 can experiencesignificant jarring movements during the landing after the drop, duringsorting and placing the formed shaped smokeless tobacco bodies 100 intoa container 300, closing, labeling, shrink wrapping, and bulk packagingthe container 300, shipping containers to retail locations, stocking thecontainers at a retail location, and having an adult tobacco consumerpurchase and carry around the container 300. The fiber-wrapped smokelesstobacco products 100 provided herein, however, can retain theirstructural integrity due to the fiber wrapping.

Melt-Blowing Processes

Referring to FIGS. 2A and 2B, melt-blown polymeric fibers 130 can beproduced using a melt-blowing device 120 and form a coating 110 offibers around a body 105. Melt-blowing is an extrusion process wheremolten polymeric resins are extruded through an extrusion die (i.e., aspinneret) and gas is introduced to draw the filaments to producepolymeric fibers. The gas can be heated air blown at high velocitythrough orifices that surround each spinneret. In some cases, layers ofhot air are blown through slots between rows of spinnerets—the strandsof polymeric material are attenuated by being trapped between two layersof air. Other methods of delivering the attenuating gas (e.g., heatedair) are possible. FIG. 2C depicts an exemplary arrangement of polymerorifices and air orifices for a melt-blowing devices 120. Othermelt-blowing devices are described in U.S. Pat. Nos. 4,380,570;5,476,616; 5,645,790; and 6,013,223 and in U.S. Patent Applications US2004/0209540; US 2005/0056956; US 2009/0256277; US 2009/0258099; and US2009/0258562, which are hereby incorporated by reference.

A melt-blowing device 120 can include a polymer extruder that pushesmolten polymer at low or high melt viscosities through a plurality ofpolymer orifices 122. The melt-blowing device 120 includes one or moreheating devices that heat the polymer as it travels through themelt-blowing device 120 to ensure that the polymer remains above itsmelting point and at a desired melt-blowing temperature. As the moltenpolymer material exits the polymer orifice 122, the polymer material isaccelerated to near sonic velocity by gas being blown in parallel flowthrough one or more air orifices 124. The air orifices 124 can beadjacent to the polymer orifices 122. The air orifices 124 may surroundeach polymer orifice 122. In some cases, the air orifices 124 can berounded. Each combination of a polymer orifice 122 with surrounding airorifices 124 is called a spinneret 129. For example, the melt-blowingdevice 120 can have between 10 and 500 spinnerets 129 per square inch.The polymer orifices 122 and the gas velocity through gas orifices 124can be combined to form fibers of 100 microns or less. In some cases,the spinnerets each have a polymer orifice diameter of 30 microns orless. In some cases, the fibers have diameters of between 0.5 micronsand 5 microns. The factors that affect fiber diameter includethroughput, melt temperature, air temperature, air pressure, spinneretdesign, material, distance from the drum, spinneret design, and materialbeing processed. In some cases, the spinnerets 129 each have a polymerorifice diameter of less than 900 microns. In some cases, the spinnerets129 each have a polymer orifice diameter of at least 75 microns. Theaverage polymer orifice diameter can range from 75 microns to 1800microns. In some cases, the average polymer orifice diameter can bebetween 150 microns and 400 microns. In some cases, polymer orificediameters of about 180 microns, about 230 microns, about 280 microns, orabout 380 microns are used.

Smokeless tobacco can also be enrobed or wrapped with melt-blownpolymeric fibers by dropping bodies 105 including smokeless tobacco Tthrough a stream 130 of melt-blown polymeric fibers exiting an array ofmelt-blowing spinnerets. Bodies 105 including smokeless tobacco T,binder B, flavorants F, and other possible additives can be formed in amixing/molding device 140. As each body 105 passes through the stream130 of melt-blown polymeric fibers, the fibers wrap around each body toform a fiber wrapping 110. The melt-blown fibers can be at a temperatureabove or below the polymer melt temperature as the fibers impact thebodies 105. In some cases, a spray of quenching fluid 184 (e.g., air) ispositioned to quench the polymeric fibers as they exit the die and priorto contacting the bodies 105. In some cases, air streams can be used torotate the smokeless tobacco body 105 as it falls through the stream 130to enhance to coverage of the body 105 with polymeric fibers. In somecases, one or more holding devices (e.g., needle-like devices) canpressed into the body 105 to hold the body in one or more desiredorientations as the body is passed through the stream 130. In somecases, if the process fails to fully encapsulate the smokeless tobaccobodies 105, the backside of the bodies can also be sealed in adownstream process. In some cases, a body 105 is cycled through theprocess multiple times to ensure that it is fully wrapped. Excessmelt-blown fibers can be rolled onto a vacuum roll 132 and then onto awind up roll 138, and possibly used in other products/processes.

Centrifugal Force Spinning Processes

Centrifugal force spinning is a process where centrifugal force is usedto create and orient polymeric fibers. FIGS. 3A-3E depict an exemplarycentrifugal force spinning apparatus. As shown, a spinneret 420 holdspolymeric material 415 and is rotated at high speeds with a motor 450 toproduce polymeric fibers 430 that are deposited onto a fiber collector432. FIG. 3B depicts a close-up of the spinneret 420 showing twoorifices 422. Any number of orifices 422 can be used. The fibercollector 432 can be a continuous drum or a series of spaced collectionfingers. As the spinneret 420 rotates, the polymeric material (in aliquid state) is pushed to the orifices 422 lining the outer wall of thespinneret 420. As the polymeric material enters the orifice chamber,molecules disentangle and then align directionally. Centrifugal andhydrostatic forces combine to initiate a liquid material jet. Theexternal aerodynamic environment combined with the inertial force ofcontinued rotation further applies shear forces and promote coolingand/or solvent evaporation to further stretch the fiber. The inertiaforce can stretch molecular chains into the nanoscale and the airturbulence can apply a shear force. A body including smokeless tobaccocan be passed through the streams of centrifugal force spun polymereither by dropping the body through the stream 430 or by using holdingdevices (e.g., needle-like holding device) to move and/or rotate a body105 within a polymer deposition zone (e.g., in a collection drum 432).

Polymeric Fibers

In some cases, the fibers are mouth-stable fibers. The mouth-stablefibers can have low extractables, have FDA food contact approval, and/orbe manufactured by suppliers who are GMP approved. Highly desirable arematerials that are easy to process and relatively easy to approve fororal use (e.g. quality, low extractables, has FDA food contact approval,suppliers are GMP approved). In some cases, the mouth-stable structuralfibers are elastomers. Elastomers can provide webs with improvedelongation and toughness. Suitable elastomers include VISTAMAX(ExxonMobil) and MD-6717 (Kraton). In some cases, elastomers can becombined with polyolefins at ratios ranging from 1:9 to 9:1. Forexample, elastomers (such as VISTAMAX or MD-6717) can be combined withpolypropylene.

Mouth-dissolvable fibers could be made from hydroxypropyl cellulose(HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH),PVP, polyethylene oxide (PEO), starch and others. These fibers couldcontain flavors, sweeteners, milled tobacco and other functionalingredients. The fibers 130 can, in some cases, be formed by extrusionor by solvent processes. In some cases, mouth dissolvable fibers can becombined with mouth-stable fibers to wrap the bodies 105 as providedherein. For example, alternating layers of mouth dissolvable fibers andmouth-stable fibers can be deposited on a body 105.

Colorants C and/or fillers can also be added to the polymer P in themelt-blowing device 120. The hydraulic permittivity of the fabric canalso be increased by compounding the polymer P with a filler prior tomelt-blowing the polymeric material. The hydraulic permittivity is therate of fluid transfer through a substrate. In some cases, a colorant Ccan be used as the filler. For example, a brown colorant C can be addedto a feed hopper of the extruder along with a polymer material P (e.g.,polypropylene) prior to melt blowing the polymer into the fibers. Inaddition to improving the hydraulic permittivity, the colorant canimprove the aesthetic appeal of the fiber-wrapped smokeless tobaccoproduct 100. For example, a brown colorant can make a wrapped moistsmokeless tobacco product appear moist. Table 1 below compares amelt-blown polypropylene polymer fabrics produced with and without browncolorant.

TABLE 1 Analysis Results 3962 PP 3962 PP Polymer Polymer w/ w/o ColorBrown Color Sample # 2 1 5-2-MB-006 5-2-MB-001 PP3962, PP3962, Techmer8%, Replicates 3 g/m² 3.1 g/m² 6 Tensile Integrity (mJ) 5.73 7.19 Stdev0.89 1.23 15 Permittivity (relative 8 3 liquid flow through rate, s)Stdev 0.5 0.4 Basis Weight (g/m²) 3.0 3.1

As shown, the polypropylene having the brown colorant had an increasedtensile integrity and a permittivity. Sample 2 includes eight weightpercent of a brown color called Techmer. The colorant and the polymercan be compounded and pelletized prior to melt-blowing the polymer toensure a consistent ratio of colorant C to polymer P. In some cases, thecolorant C can be a liquid and can be injected into the polymericmaterial.

In some cases, the filler can include milled tobacco material. Forexample, milled tobacco could be combined into a polymeric structuralfiber such that the polymeric material at least partially encapsulatesthe milled tobacco. For example, milled tobacco could be added to amolten polymer (e.g., polypropylene) in amounts of up to about 80% andextruded in a melt-blowing or centrifugal force spinning process. Themilled tobacco can provide a unique texture or consumer experience whilethe polymeric material remains mouth-stable and cohesive.

As discussed above, the polymeric fibers can contact the bodies 105 at atemperature greater than the melt temperature of the polymer. In somecases, however, the polymeric fibers can be quenched and/or treated witha surfactant prior to contacting the bodies 105. Water vapor can be usedto cool the polymeric material. For example, water vapor 184 from aspout 186 can be directed into the stream 130 of molten strands ofpolymeric material to “quench” the polymeric strands and form thefibers. For example, a mist 184 can be aimed towards the spinnerets 129of the melt-blowing device 120. A fine mist of water vapor or surfactantor air can quickly cool the strands below the polymer melt temperature.In some cases, quenched melt-blown fibers can have improved softness andfiber/web tensile strength.

A surfactant treatment can also be applied to the fibers 130. In somecases, a surfactant S is applied to the polymeric fibers as they exitthe spinnerets 129 of the melt-blowing device 120 or the orifices 422 ofthe centrifugal force spinning spinneret 420. In some cases, surfactantcan be applied as a mist 184 (either with or without water). In somecases, the surfactant applied as a mist 184 can quench the polymericfibers. In some cases, the surfactant can be applied in an extrusionprocess. In some cases, a mixture of water and surfactant can beatomized an applied as mist 184. Sweeteners and/or flavorants can alsobe atomized and applied to the polymeric fibers in mist 184.

Quenching the polymer can modify the crystallinity of the polymermaterial to improve tensile strength. The surfactant can improve thehydraulic permittivity of the fiber wrap 110 to improve moisture andflavor release from the product 100. The hydraulic permittivity is therate of fluid transfer through a substrate. Table 2 compares fabricsproduced with and without surfactant treatment and water quenching. Asshown in Table 2, Sample 1 (produced without water quenching or asurfactant treatment) had a tensile integrity of 5.73 mJ and apermittivity of 8 seconds. Quenching with water (Sample 3) improved thetensile integrity to 7.09 mJ. Applying surfactant mixtures at differentpercentages also resulted in improved tensile integrity values (Samples5-7). Added surfactant in amounts of 0.4% or greater (Samples 2, 6, and7) increase the permittivity to 6 seconds.

TABLE 2 Analytical Results Comparing Non-Treated & Surfactant TreatedMelt Blown Material Analysis Results 3962 PP 3982 PP 3952 PP 3962 PP3962 PP 3962 PP 3962 PP Polymer Polymer Polymer Polymer Polymer PolymerPolymer Sample # 1 2 3 4 5 8 7 5-2- 5-2-MB- 5-2- 5-2-MB-002 5-2- 5-2-5-2- MB-001 001 PP3963 MB-002 PP3962, Water MB-003 MB-004 MB-005 PP3962LAB PP3962, Quenching, 3 PP3962, PP3962, PP3962, Standard ADDED Waterg/m2 LAB Surfactant Surfactant Surfactant MB SUR- Quenching, ADDED SUR-0.2%, 0.4%, 0.6%, Material FACTANT 3 g/m² FACTANT 3 g/m² 3 g/m² 3 g/m²Tensile Integrity (mJ) 5.73 7.09 6.94 6.10 6.12 Stdev 0.89 0.75 0.851.19 0.67 Permittivity (relative liquid 8 6 7 6 8 6 6 flow through rate,s) Stdev 0.5 0.3 0.4 0.5 0.0 0.0 0.0 Basis Weight (g/m2) 3.0 3.0 3.0 3.03.0 3.0 3.0

The tensile integrity of the wrapped fiber can also be improved bybonding fibers together. In some cases, the wrapped fiber can be heatbonded at intersection points. The heating of the polymeric material toa temperature above its melt temperature can be accomplished by usingelectrically heated surfaces, ultrasonic bonding, infrared energy, radiofrequency energy, and microwave energy. Stitch bonding, point bonding,and quilting are methods of applying patterns to nonwoven fabrics. Theseare forms of thermal bonding typically achieved with ultrasonic bondingprocesses although other energy sources and related equipment can beused to create particular patterns of bonding within the network offibers.

Product Components

The smokeless tobacco products 100 include smokeless tobacco 105 andpolymeric material 110. The smokeless tobacco product 100 can optionallyinclude one or more flavorants and other additives. In some cases,smokeless tobacco 105 includes smokeless tobacco. In some cases, thesmokeless tobacco can be moist, cured, fermented smokeless tobacco. Insome cases, the smokeless tobacco can be non-fermented tobacco. In somecases, the smokeless tobacco can be vacuum treated tobacco. Theparticular composition may, in part, determine the flavor profile andmouth feel of the smokeless tobacco products 100.

Polymeric Materials

Suitable polymeric materials for the fibers wrapping the smokelesstobacco include one or more of the following polymer materials: acetals,acrylics such as polymethylmethacrylate and polyacrylonitrile, alkyds,polymer alloys, allyls such as diallyl phthalate and diallylisophthalate, amines such as urea, formaldehyde, and melamineformaldehyde, epoxy, cellulosics such as cellulose acetate, cellulosetriacetate, cellulose nitrate, ethyl cellulose, cellulose acetate,propionate, cellulose acetate butyrate, hydroxypropyl cellulose,hydroxypropyl methyl cellulose, carboxymethyl cellulose, cellophane andrayon, chlorinated polyether, coumarone-indene, epoxy, polybutenes,fluorocarbons such as PTFE, FEP, PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF,furan, hydrocarbon resins, nitrile resins, polyaryl ether, polyarylsulfone, phenol-aralkyl, phenolic, polyamide (nylon), poly(amide-imide), polyaryl ether, polycarbonate, polyesters such asaromatic polyesters, thermoplastic polyester, PBT, PTMT, (polyethyleneterephthalate) PET and unsaturated polyesters such as SMC and BMC,thermoplastic polyimide, polymethyl pentene, polyolefins such as LDPE,LLDPE, HDPE, and UHMWPE, polypropylene, ionomers such as PD and polyallomers, polyphenylene oxide, polyphenylene sulfide, polyurethanes(such as DESMOPAN DP 9370A available from Bayer), poly p-xylylene,silicones such as silicone fluids and elastomers, rigid silicones,styrenes such as PS, ADS, SAN, styrene butadiene latricies, and styrenebased polymers, suflones such as polysulfone, polyether sulfone andpolyphenyl sulfones, polymeric elastomers, and vinyls such as PVC,polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, polyvinylbutyrate, polyvinyl formal, propylene-vinyl chloride copolymer,ethylvinyl acetate, and polyvinyl carbazole, polyvinyl pyrrolidone, andpolyethylene oxide, ethylene vinyl alcohol, sugar alcohols, andstarches.

The polymeric material can include multiple materials. In some cases,structural fibers of a first polymeric material are interspersed orlayered with structural fibers of a second polymeric material. Forexample, a lower melting polymer can function as a binder which may be aseparate fiber interspersed with higher melting structural polymericfibers. In some cases, structural fibers can include multiple componentsmade of different materials. For example, a lower melting sheath cansurround a higher melting core, which can help with the conformingand/or bonding processes. The components of a multi-component fiber canalso be extruded in a side-by-side configuration. For example, differentpolymeric materials can be co-extruded and drawn in a melt-blowing orspun bond process to form the multi-component structural fibers.

In some cases, the polymeric material includes one mouth-stable materialand one mouth-dissolvable material such that the smokeless tobaccoproduct will loosen but remain cohesive as the mouth-dissolvablematerial dissolves away. In some cases, a network of structuralpolymeric fibers includes mouth-dissolvable polymeric fibers andmouth-stable polymeric fibers. As used herein, “mouth-stable” means thatthe material remains cohesive when placed in a mouth of an adult tobaccoconsumer for 1 hour. As used herein, “mouth-dissolvable” means that thematerial breaks down within 1 hour after being exposed to saliva andother mouth fluids when placed in a mouth of an adult tobacco consumer.Mouth-dissolvable materials include hydroxypropyl cellulose (HPC),hydroxypropyl methyl cellulose (HPMC), polyvinyl alcohol (PVOH), PVP,polyethylene oxide (PEO), carboxyl methyl cellulose (CMC), starch, gums,maltodextrin, sugar alcohols (e.g., sorbitol), and others.Mouth-dissolvable materials could be combined with flavors, sweeteners,milled tobacco and other functional ingredients. In some cases,multi-component fibers include a mouth-stable material and amouth-dissolvable material.

In some cases, the polymeric material includes reconstituted cellulosicfibers. Reconstituted cellulosic fibers can be created from variouswoods and annual plants by physically dissolving the wood or plantmaterial in a suitable solvent, such as methylmorpholine oxide (MNNO)monohydrate. The concentration of cellulose in the solution can bebetween 6 weight and 15 weight percent. The solution can then be spun(e.g., melt-blown or spun bond) at a temperature of between 70° C. and120° C. to create reconstituted cellulosic fibers. In some cases, thereconstituted cellulosic fibers are made using tobacco material (e.g.,tobacco stems, leaves). Reconstituted tobacco cellulosic fibers can thenbe intermingled with smokeless tobacco having natural cellulosic fibersto create a fiber-wrapped smokeless tobacco product havingtobacco-derived structural fibers. The reconstituting process changesthe composition of the tobacco and removes soluble tobacco components.

The polymeric material can also be combined with milled tobacco prior tocontacting the tobacco with the smokeless tobacco. In some cases, themilled tobacco can have an average particle size of between 0.01 micronsand 200 microns. For example, milled tobacco could be combined into apolymeric structural fiber such that the polymeric material at leastpartially encapsulates the milled tobacco. For example, milled tobaccocould be added to a molten polymer (e.g., polypropylene) in amounts ofup to about 80% and extruded in a melt-blowing or spun bond process. Themilled tobacco can provide a unique texture while the polymeric materialremains mouth-stable and cohesive.

The amount of polymeric material used in the smokeless tobacco product100 depends on the desired flavor profile and desired mouth feel. Insome cases, the smokeless tobacco product 100 includes less than 200 mgof polymer for a single product 100. In some cases, a product 100 caninclude between 5 and 100 mg of polymeric material, between 60 and 80 mgof polymeric material, between 10 and 50 mg of polymeric material, orbetween 25 and 75 mg of polymeric material. In some cases, a product 100includes between 0.1% and 10% by weight of polymeric material, between0.4% and 5% by weight of polymeric material, between 0.5% and 2% byweight of polymeric material, between 2% and 4% by weight of polymericmaterial, or between 1% and 3% by weight of polymeric material. In somecases, the basis weight of the wrapping of polymeric fibers 110 can havea basis weight of less than 30 gsm, less than 25 gsm, less than 20 gsm,less than 15 gsm, less than 10 gsm, less than 5 gsm, less than 4 gsm,less than 3 gsm, less than 2 gsm, or less than 1 gsm. In some cases, thewrapping of polymeric fibers 110 can have a basis weight of between 0.5gsm and 4 gsm, between 1 gsm and 3 gsm, or of about 2 gsm.

Tobacco

Smokeless tobacco is tobacco suitable for use in an orally used tobaccoproduct. By “smokeless tobacco” it is meant a part, e.g., leaves, andstems, of a member of the genus Nicotiana that has been processed.Exemplary species of tobacco include N. rustica, N. tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos. In addition to fermentation, the tobacco canalso be processed using other techniques. For example, tobacco can beprocessed by heat treatment (e.g., cooking, steam treating, toasting),flavoring, enzyme treatment, expansion and/or curing. Both fermented andnon-fermented tobaccos can be processed using these techniques. In somecases, the tobacco can be unprocessed tobacco. Specific examples ofsuitable processed tobaccos include, dark air-cured, dark fire cured,burley, flue cured, and cigar filler or wrapper, as well as the productsfrom the whole leaf stemming operation. In some cases, smokeless tobaccoincludes up to 70% dark tobacco on a fresh weight basis.

Tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. Fermenting typically is characterized by high initialmoisture content, heat generation, and a 10 to 20% loss of dry weight.See, e.g., U.S. Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and5,372,149. In addition to modifying the aroma of the leaf, fermentationcan change the color, texture, taste, and sensorial attributes of aleaf. Also during the fermentation process, evolution gases can beproduced, oxygen can be taken up, the pH can change, and the amount ofwater retained can change. See, for example, U.S. Publication No.2005/0178398 and Tso (1999, Chapter 1 in Tobacco, Production, Chemistryand Technology, Davis & Nielsen, eds., Blackwell Publishing, Oxford).Cured, or cured and fermented tobacco can be further processed (e.g.,cut, expanded, blended, milled or comminuted) prior to incorporationinto the smokeless tobacco product. The tobacco, in some cases, is longcut fermented cured moist tobacco having an oven volatiles content ofbetween 10 and 61 weight percent prior to mixing with the polymericmaterial and optionally flavorants and other additives.

The tobacco can, in some cases, be prepared from plants having less than20 μg of DVT per cm² of green leaf tissue. For example, the tobaccoparticles can be selected from the tobaccos described in U.S. PatentPublication No. 2008/0209586, which is hereby incorporated by reference.Tobacco compositions containing tobacco from such low-DVT varietiesexhibits improved flavor characteristics in sensory panel evaluationswhen compared to tobacco or tobacco compositions that do not havereduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g.,flue-cured, barn-cured, fire-cured, air-cured or sun-cured. See, forexample, Tso (1999, Chapter 1 in Tobacco, Production, Chemistry andTechnology, Davis & Nielsen, eds., Blackwell Publishing, Oxford) for adescription of different types of curing methods. Cured tobacco isusually aged in a wooden drum (i.e., a hogshead) or cardboard cartons incompressed conditions for several years (e.g., two to five years), at amoisture content ranging from 10% to about 25%. See, U.S. Pat. Nos.4,516,590 and 5,372,149. Cured and aged tobacco then can be furtherprocessed. Further processing includes conditioning the tobacco undervacuum with or without the introduction of steam at varioustemperatures, pasteurization, and fermentation. Fermentation typicallyis characterized by high initial moisture content, heat generation, anda 10 to 20% loss of dry weight. See, e.g., U.S. Pat. Nos. 4,528,993,4,660,577, 4,848,373, 5,372,149; U.S. Publication No. 2005/0178398; andTso (1999, Chapter 1 in Tobacco, Production, Chemistry and Technology,Davis & Nielsen, eds., Blackwell Publishing, Oxford). Cure, aged, andfermented smokeless tobacco can be further processed (e.g., cut,shredded, expanded, or blended). See, for example, U.S. Pat. Nos.4,528,993; 4,660,577; and 4,987,907.

The smokeless tobacco can be processed to a desired size. For example,long cut smokeless tobacco typically is cut or shredded into widths ofabout 10 cuts/inch up to about 110 cuts/inch and lengths of about 0.1inches up to about 1 inch. Double cut smokeless tobacco can have a rangeof particle sizes such that about 70% of the double cut smokelesstobacco falls between the mesh sizes of −20 mesh and 80 mesh. Otherlengths and size distributions are also contemplated.

The smokeless tobacco can have a total oven volatiles content of about10% by weight or greater; about 20% by weight or greater; about 40% byweight or greater; about 15% by weight to about 25% by weight; about 20%by weight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” smokeless tobacco typically refers to tobacco that has anoven volatiles content of between about 40% by weight and about 60% byweight (e.g., about 45% by weight to about 55% by weight, or about 50%by weight). As used herein, “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110° C. for 3.25 hours. Thefiber-wrapped smokeless tobacco product can have a different overalloven volatiles content than the oven volatiles content of the smokelesstobacco used to make the fiber-wrapped smokeless tobacco product. Theprocessing steps described herein can reduce or increase the ovenvolatiles content. The overall oven volatiles content of thefiber-wrapped smokeless tobacco product is discussed below.

The fiber-wrapped smokeless tobacco product can include between 15weight percent and 85 weight percent smokeless tobacco on a dry weightbasis. The amount of smokeless tobacco in a fiber-wrapped smokelesstobacco product on a dry weight basis is calculated after drying thefiber-wrapped smokeless tobacco product in a pre-warmed forced draftoven at 110° C. for 3.25 hours. The remaining non-volatile material isthen separated into tobacco material and polymeric material. The percentsmokeless tobacco in the fiber-wrapped smokeless tobacco product iscalculated as the weight smokeless tobacco divided by the total weightof the non-volatile materials. In some cases, the fiber-wrappedsmokeless tobacco product includes between 20 and 60 weight percenttobacco on a dry weight basis. In some cases, the fiber-wrappedsmokeless tobacco product includes at least 28 weight percent tobacco ona dry weight basis. For example, a fiber-wrapped smokeless tobaccoproduct can include a total oven volatiles content of about 57 weightpercent, about 3 weight percent polymeric material, and about 40 weightpercent smokeless tobacco on a dry weight basis.

In some cases, a plant material other than tobacco is used as a tobaccosubstitute in the fiber-wrapped smokeless tobacco product. The tobaccosubstitute can be an herbal composition. Herbs and other edible plantscan be categorized generally as culinary herbs (e.g., thyme, lavender,rosemary, coriander, dill, mint, peppermint) and medicinal herbs (e.g.,Dahlias, Cinchona, Foxglove, Meadowsweet, Echinacea, Elderberry, Willowbark). In some cases, the tobacco is replaced with a mixture ofnon-tobacco plant material. Such non-tobacco compositions may have anumber of different primary ingredients, including but not limited to,tea leaves, red clover, coconut flakes, mint leaves, ginseng, apple,corn silk, grape leaf, and basil leaf. The plant material typically hasa total oven volatiles content of about 10% by weight or greater; e.g.,about 20% by weight or greater; about 40% by weight or greater; about15% by weight to about 25% by weight; about 20% by weight to about 30%by weight; about 30% by weight to about 50% by weight; about 45% byweight to about 65% by weight; or about 50% by weight to about 60% byweight.

Binders

Binders can be used to bind together smokeless tobacco material to forma body, which can then be encased or wrapped with polymeric fibers.Binders suitable for use in the fiber-wrapped smokeless tobacco productprovided herein include orally compatible polymers, such as cellulosics(e.g., carboxymethyl cellulose (CMC), hydroxypropyl cellulose (HPC),hydroxyethyl cellulose (HEC), hydroxypropyl methyl cellulose (HPMC), andmethyl cellulose (MC)); natural polymers (e.g., starches and modifiedstarches, konjac, collagen, inulin, soy protein, whey protein, casein,and wheat gluten); seaweed-derived polymers (e.g., carrageenan (kappa,iota, and lambda); alginates, (and propylene glycol alginate),microbial-derived polymers (e.g., xanthan, dextrin, pullulan, curdlan,and gellan); extracts (e.g., locust bean gum, guar gum, tara gum, gumtragacanth, pectin (lo methoxy and amidated), agar, zein, karaya,gelatin, psyllium seed, chitin, and chitosan), exudates (e.g., gumacacia (arabic) and shellac), synthetic polymers (e.g., polyvinylpyrrolidone, polyethylene oxide, and polyvinyl alcohol)).

The binder, in some cases, is guar gum, xanthan, cellulose, or acombination thereof. The cellulose can be carboxymethyl cellulose (CMC).Guar gum, xanthan, CMC, and some combinations thereof can be obtainedfrom, for example, TIC Gums Inc., located in White Marsh, Md. and atwww.ticgums.com. Guar gum is sold by TIC Gums Inc. under the trade nameGUARNT. Carboxymethyl cellulose (CMC) is sold by TIC Gums Inc. under thetrade name TICALOSE. Xanthan is sold by TIC Gums Inc. under the tradename TICAXAN. TIC Gums Inc. also sells some mixed binders, such as themixed binder systems sold under the trade names TICALOID and TICAFILM.In some cases, TICALOID LITE Powder is used as the binder in thepreformed smokeless tobacco products.

The binder can be present in amounts that allow the fiber-wrappedsmokeless tobacco product 100 to remain cohesive during a pass throughthe stream 130. In some cases, the fiber-wrapped smokeless tobaccoproduct 100 includes at least 0.05 weight percent binder. Thefiber-wrapped smokeless tobacco product 100 has, in some cases, lessthan 5.0 weight percent binder. The fiber-wrapped smokeless tobaccoproduct 100 has, in some cases, less than 1.0 weight percent binder. Insome cases, the binder of each fiber-wrapped smokeless tobacco product100 is between 0.05 and 0.5 weight percent of the preformed smokelesstobacco product. The binder of each fiber-wrapped smokeless tobaccoproduct 100 can also be in an amount of between 0.1 and 0.4 weightpercent.

Flavorants and Additives

Flavors and other additives can be included in the compositions andarrangements described herein and can be added to the fiber-wrappedsmokeless tobacco products 100 at any point in the process of making thefiber-wrapped smokeless tobacco products. For example, any of theinitial components, including the polymeric material, can be provided ina flavored form. In some cases, flavorants and/or other additives areincluded in the smokeless tobacco. In some cases, flavorants and/orother additives are absorbed into to the smokeless tobacco product 100after the polymeric material and the tobacco are combined. In somecases, flavorants and/or other additives are sprayed onto a stream 130as part of a quenching and/or surfactant mist 184. Alternatively oradditionally, flavor can be applied prior to being further processed(e.g., cut or punched into shapes) or flavor can be applied prior topackaging. Referring to FIG. 4M, for example, some embodiments of asmokeless tobacco product 100M can be equipped with flavors, in the formof flavor strips 116 or can be completely enrobed with dissolvableflavor film.

Suitable flavorants include wintergreen (i.e., methyl salicylate),cherry and berry type flavorants, various liqueurs and liquors such asDramboui, bourbon, scotch, whiskey, spearmint, peppermint, lavender,cinnamon, cardamon, apium graveolents, clove, cascarilla, nutmeg,sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemonoil, orange oil, Japanese mint, cassia, caraway, cognac, jasmin,chamomile, menthol, ilangilang, sage, fennel, piment, ginger, anise,coriander, coffee, liquorish, and mint oils from a species of the genusMentha. Mint oils useful in some cases of the fiber-wrapped smokelesstobacco products 100 include spearmint and peppermint.

Flavorants can also be included in the form of flavor beads (e.g.,flavor capsules, flavored starch beads, flavored gelatin beads), whichcan be dispersed within the fiber-wrapped smokeless tobacco product(e.g., in a nonwoven network of polymeric structural fibers). Forexample, the fiber-wrapped smokeless tobacco product could include thebeads described in U.S. Patent Application Publication 2010/0170522,which is hereby incorporated by reference.

In some cases, the amount of flavorants in the fiber-wrapped smokelesstobacco product 100 is limited to less than 10 weight percent in sum. Insome cases, the amount of flavorants in the fiber-wrapped smokelesstobacco product 100 is limited to be less than 5 weight percent in sum.For example, certain flavorants can be included in the fiber-wrappedsmokeless tobacco product in amounts of about 3 weight percent.

Other optional additives include as fillers (e.g., starch, di-calciumphosphate, lactose, sorbitol, mannitol, and microcrystalline cellulose),soluble fiber (e.g., Fibersol from Matsushita), calcium carbonate,dicalcium phosphate, calcium sulfate, and clays), lubricants (e.g.,lecithin, stearic acid, hydrogenated vegetable oil, canola oil, mineraloil, polyethylene glycol 4000-6000 (PEG), sodium lauryl sulfate (SLS),glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate,talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerolmonostearate, propylene glycol monostearate, and acetylatedmonoglycerides)), plasticizers (e.g., glycerine (SP?), propylene glycol,polyethylene glycol, sorbitol, mannitol, triacetin, and 1,3 butanediol), stabilizers (e.g., ascorbic acid and monosterol citrate, BHT, orBHA), artificial sweeteners (e.g., sucralose, saccharin, and aspartame),disintegrating agents (e.g., starch, sodium starch glycolate, crosscaramellose, cross linked PVP), pH stabilizers, salt, or other compounds(e.g., vegetable oils, surfactants, and preservatives). Some compoundsdisplay functional attributes that fall into more than one of thesecategories. For example, propylene glycol can act as both a plasticizerand a lubricant and sorbitol can act as both a filler and a plasticizer.As noted above, fillers or colorants can be added to the polymer priorto melt-blowing the polymer in order to increase the permittivity of thewrapped fibers.

Oven volatiles, such as water, may also be added to the fiber-wrappedsmokeless tobacco product 100 to bring the oven volatiles content of thefiber-wrapped smokeless tobacco product into a desired range. In somecases, flavorants and other additives are included in a hydratingliquid.

Oven Volatiles

The fiber-wrapped smokeless tobacco product 100 can have a total ovenvolatiles content of between 10 and 61 weight percent. In some cases,the total oven volatiles content is at least 40 weight percent. The ovenvolatiles include water and other volatile compounds, which can be apart of the tobacco, the polymeric material, the flavorants, and/orother additives. As used herein, the “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110° C. for 3.25 hours. Someof the processes may reduce the oven volatiles content (e.g., heatingthe composite or contacting the smokeless tobacco with a heatedpolymeric material), but the processes can be controlled to have anoverall oven volatiles content in a desired range. For example, waterand/or other volatiles can be added back to the fiber-wrapped smokelesstobacco product to bring the oven volatiles content into a desiredrange. In some cases, the oven volatiles content of the fiber-wrappedsmokeless tobacco product 100 is between 4 and 61 weight percent. Insome cases, the oven volatiles content of the fiber-wrapped smokelesstobacco product 100 is between 47 and 61 weight percent. For example,the oven volatiles content of smokeless tobacco 105 used in the variousprocessed described herein can be about 57 weight percent. In somecases, the oven volatiles content can be between 10 and 30 weightpercent.

Exemplary Packaging System and Method of Use

Referring to FIG. 1C, some embodiments of a smokeless tobacco system 300can include one or more smokeless tobacco products 100 containingsmokeless tobacco 105 stabilized by polymeric fibers 110. A plurality ofsmokeless tobacco products 100 can be arranged in an interior space of abottom container 302 that mates with a lid 304. The plurality of thefiber-wrapped smokeless tobacco products 100 arranged in the container300 can all have a substantially similar shape so that an adult tobaccoconsumer can conveniently select any of the similarly shaped smokelesstobacco products 100 therein and receive a generally consistent portionof the smokeless tobacco 105.

Still referring to FIG. 1C, the bottom container 302 and lid 304 canreleasably mate at a connection rim 303 so as to maintain freshness andother product qualities of smokeless tobacco products 100 containedtherein. Such qualities may relate to, without limitation, texture,flavor, color, aroma, mouth feel, taste, ease of use, and combinationsthereof. In particular, the bottom container 302 may have a generallycylindrical shape and include a base and a cylindrical side wall that atleast partially defines the interior space 301. In some cases, thecontainer is moisture-tight. Certain containers can be air-tight. Theconnection rim 303 formed on the container 302 provides a snap-fitengagement with the lid 304. It will be understood from the descriptionherein that, in addition to the container 300, many other packagingoptions are available to hold one or more of the smokeless tobaccoproducts 100.

In some cases, each smokeless tobacco product 100 can be configured fororal use in a manner similar to that of a pouch containing tobaccotherein. Briefly, in use, the system 300 can be configured so that anadult tobacco consumer can use a finger 314 and thumb 312 to readilygrasp at least one of the fiber-wrapped smokeless tobacco products 100for placement in a mouth of an adult tobacco consumer, thereby receivinga predetermined portion of smokeless tobacco with each smokeless tobaccoproducts 100. In some cases, the predetermined portion of smokelesstobacco is generally consistent with each of the other smokeless tobaccoproducts 100 stored in the container. For example, each fiber-wrappedsmokeless tobacco product can provide between 0.25 and 4.0 grams ofsmokeless tobacco. Accordingly, the system 300 can permit an adulttobacco consumer to receive consistent portions of smokeless tobaccowith each placement of the smokeless tobacco product 100 in his or hermouth. In some cases, the adult tobacco consumer can experience thetactile and flavor benefits of having smokeless tobacco exposed yetcontained within a mouth of the adult tobacco consumer. The texture of apolymeric material exterior surface (e.g., an exterior surface includingmelt-blown polymeric fibers) may provide an adult tobacco consumer witha pleasing mouth feel and greater fluid transfer. In particular, a lackof any seams (typically associated with a pouched smokeless tobaccoproduct) can provide a more pleasing mouth feel. In some cases, thesmokeless tobacco is a type of smokeless tobacco that is not suitablefor industrial pouching machines, such as smokeless tobacco having anaverage aspect ratio of greater than 3 (e.g., long-cut smokelesstobacco).

Product Configurations

An exemplary shape of a fiber-wrapped smokeless tobacco product 100provided herein is shown in FIG. 1B. FIG. 1B depicts a perspective viewof the fiber-wrapped smokeless tobacco product 100 having asubstantially rectangular cuboidal shape with rounded corners in thelongitudinal (lengthwise) plane. In some cases, the preformed smokelesstobacco product has a substantially rectangular cuboidal shape having alength L of between 15 mm and 50 mm, a width W of between 5 mm and 20mm, and a thickness T of between 3 mm and 10 mm. For example, asubstantially rectangular cuboidal shape could have a length L ofbetween 26 mm and 30 mm, a width W of between 10 mm and 12 mm, and athickness T of between 6 mm and 8 mm. A product having a length of 28mm, a width of 11 mm, and thickness of 7 mm could have a product weightof about 2.35 g. In other embodiments, a substantially rectangularcuboidal shape could have a length L of between 18 and 21 mm, a width Wof between 10 mm and 12 mm, and a thickness T of between 9 mm and 11 mm.In some cases, the preformed smokeless tobacco product 100 can be cubeshaped.

A smokeless tobacco product as described herein can have a number ofdifferent configurations, e.g., can have the configuration depicted inFIG. 1B, or have a shape or a layered structure that is different fromthe particular embodiment of the fiber-wrapped smokeless tobacco product100 depicted in FIG. 1B. For example, referring to FIGS. 4A-4N, thesmokeless tobacco products 100A-K can be formed in a shape that promotesimproved oral positioning for the adult tobacco consumer, improvedpackaging characteristics, or both. In some circumstances, thefiber-wrapped smokeless tobacco product can be configured to be: (A) anelliptical shaped fiber-wrapped smokeless tobacco product 100A; (B) anelongated elliptical shaped fiber-wrapped smokeless tobacco product100B; (C) a semi-circular fiber-wrapped smokeless tobacco product 100C;(D) a square- or rectangular-shaped fiber-wrapped smokeless tobaccoproduct 100D; (E) a football-shaped fiber-wrapped smokeless tobaccoproduct 100E; (F) an elongated rectangular-shaped fiber-wrappedsmokeless tobacco product 100F; (G) boomerang-shaped fiber-wrappedsmokeless tobacco product 100G; (H) a rounded-edge rectangular-shapedfiber-wrapped smokeless tobacco product 100H; (I) teardrop- orcomma-shaped fiber-wrapped smokeless tobacco product 100I; (J)bowtie-shaped fiber-wrapped smokeless tobacco product 100J; and (K)peanut-shaped fiber-wrapped smokeless tobacco product 100K.Alternatively, the smokeless tobacco product can have differentthicknesses or dimensionality, such that a beveled fiber-wrappedsmokeless tobacco product (e.g., a wedge) is produced (see, for example,the melt-blown smokeless tobacco product depicted in FIG. 4L) or ahemi-spherical shape is produced.

Smokeless tobacco products can be cut or sliced longitudinally orlaterally to produce a variety of smokeless tobacco compositions havingdifferent tobacco/fiber profiles. For example, the texture (e.g.,softness and comfort in the mouth), taste, level of oven volatiles(e.g., moisture), flavor release profile, and overall adult tobaccoconsumer satisfaction of a melt-blown smokeless tobacco product will bedependent upon the number of concentration and distribution of smokelesstobacco, and the number of layers, thicknesses, and dimensions andtype(s) of melt-blown polymeric fibers, all of which effects the densityand integrity of the final product. Similar to previously describedembodiments, the smokeless tobacco products 100A-L depicted in FIGS.4A-L can be configured to include a predetermined portion of smokelesstobacco 105. Further, the fiber-wrapped smokeless tobacco products100A-L can be packaged in a container 300 (FIG. 1C) along with aplurality of similarly shaped smokeless tobacco products 100A-L so thatan adult tobacco consumer can conveniently select any of the similarlyshaped melt-blown smokeless tobacco products therein for oral use andreceive a substantially identical portion of the smokeless tobacco 105.

In addition to including flavorants within the smokeless tobacco 105,flavorants can be included at many different places in the process. Forexample, the melt-blown polymeric fibers can include a flavorant addedto the polymeric material prior to melt-blowing. Alternatively oradditionally, flavor can be applied to the smokeless tobacco productprior to being further processed (e.g., cut or punched into shapes), orflavor can be applied to the smokeless tobacco products prior topackaging. Referring to FIG. 4M, for example, some embodiments of asmokeless tobacco product 100M can be equipped with flavorants, in theform of flavor strips 116. The flavor strips 116 can be applied to thefiber wrapping 110 with exposed areas 115 therebetween.

The smokeless tobacco product can be manipulated in a number ofdifferent ways. For example, as shown in FIG. 4N, particular embodimentsof the smokeless tobacco product 100N can be wrapped or coated in anedible or dissolvable film. The dissolvable film can readily dissipatewhen the smokeless tobacco product 100N is placed in a mouth of theadult tobacco consumer. In addition, or in the alternative, someembodiments of the smokeless tobacco products can be embossed or stampedwith a design (e.g., a logo, an image, a trademark, a product name, orthe like). For example, a design 117 also can be embossed or stampedinto those embodiments having a dissolvable film applied thereto, asillustrated in FIG. 4N.

In some cases, the fiber-wrapped smokeless tobacco product is used incombination with other tobacco and non-tobacco ingredients to form avariety of smokeless tobacco products. For example, the fiber-wrappedsmokeless tobacco product can include flavor beads.

Experimental Data

Three samples of fiber-wrapped smokeless tobacco were made by coatingbodies of wintergreen (i.e., methyl salicylate) flavored smokelesstobacco with melt-blown fiber. The tobacco used was the same tobaccoused in the SKOAL XTRA Wintergreen Pouch, which was also used as acontrol. Each sample and the control was placed into a Wennergrenmasticator and the amount of wintergreen (methyl salicylate) releasedwas measured over time, as shown in FIG. 5. As shown, the control SkoalPouch had a faster initial release of wintergreen, but had an overalllower release of wintergreen after 60 minutes. The chewing of thefiber-wrapped smokeless tobacco samples, however, demonstrated anincreased release of wintergreen as compared to the control. FIGS. 6A-6Cshow the debris left in the masticator for each sample. FIGS. 7A-7C showthe sample products after the experiment with the masticator. As shown,sample 12-MBP-001 (FIGS. 6A and 7A) lost the most mass and had a greateroverall release of wintergreen. As shown, sample 12-MBP-002 (FIGS. 6Band 7B) lost some mass. As shown, sample 12-MBP-003 (FIGS. 6C and 7C)lost the least amount of mass and had a slowest overall release ofwintergreen, but still achieves a greater release of wintergreen thanthe control. This data shows that a greater flavor release profile canbe achieved with minimal mass reduction as compared to the control.

Other Embodiments

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. Other aspects, advantages, and modifications are withinthe scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed.

What is claimed is:
 1. A seamless fiber-wrapped smokeless tobaccoproduct comprising: smokeless tobacco; a binder binding the smokelesstobacco, the smokeless tobacco product comprising less than 0.5 weightpercent binder; and a plurality of melt-blown polymeric fiberssurrounding the smokeless tobacco, the melt-blown polymeric fibershaving a hydrophilic surface coating and having a basis weight of lessthan 10 gsm; and wherein the polymeric fibers comprisesurfactant-quenched fibers.
 2. The product of claim 1, wherein themelt-blown polymeric fibers have a basis weight of less than 5 gsm. 3.The product of claim 1, wherein the smokeless tobacco comprises a highmoisture tobacco.
 4. The product of claim 1, wherein the polymericfibers have a diameter of less than 100 microns.
 5. The product of claim1, wherein the polymeric fibers conform to fibrous structures of thesmokeless tobacco.
 6. The product of claim 1, wherein the polymericfibers have a diameter of less than 30 microns.
 7. The product of claim1, wherein the polymeric fibers are melt-blown fibers having a diameterof between 0.5 and 10.0 microns.
 8. The product of claim 1, wherein thepolymeric fibers comprise polypropylene.
 9. The product of claim 1,wherein the polymeric fibers comprise at least two different materials.10. The product of claim 9, wherein the polymeric fibers comprise fibersformed by a compounded polymer comprising a colorant.
 11. The product ofclaim 9, wherein polymeric fibers are composite polymeric fibers formedby the coextrusion of at least two different polymeric materials. 12.The product of claim 11, wherein at least one of the polymeric materialsis mouth-stable and at least one of the polymeric materials ismouth-dissolvable.
 13. The product of claim 1, wherein the product hasan overall oven volatiles content of about 4% by weight to about 61% byweight.
 14. A seamless pouched smokeless tobacco product comprising: anon-tobacco cellulosic mixture; a binder dispersed in the non-tobaccocellulosic mixture; and a plurality of melt-blown or centrifugal forcespun polymeric fibers surrounding the non-tobacco cellulosic mixture,the polymeric fibers having a hydrophilic surface coating and having abasis weight of less than 10 gsm; wherein the polymeric fibers comprisesurfactant-quenched fibers.
 15. The product of claim 14, wherein thenon-tobacco cellulosic mixture comprises bamboo fiber.
 16. The productof claim 14, wherein the polymeric fibers are centrifugal force spunfibers having a diameter of between 0.01 microns and 1.0 micron.
 17. Theproduct of claim 14, wherein the product comprises between 0.1 and 0.5weight percent of the binder.
 18. The product of claim 17, wherein thebinder comprises guar gum, xanthan gum, cellulose ether, or acombination thereof.
 19. A seamless fiber-wrapped smokeless tobaccoproduct comprising: smokeless tobacco; and a fiber wrap comprising aplurality of melt-blown polymeric fibers surrounding the smokelesstobacco, the melt-blown polymeric fibers comprise a colorant forimproving the hydraulic permittivity of the fiber wrap.